Food Manufacturing Standard

Transcription

1 Food Manufacturing Standard Author: Mary Salmon Applicable to: Product: All Food Country: Group Date Issued: 28th Nov 2007 Date Revised: 25 th Feb 2008 Revision Due: 25 th Feb 2009 Legal and Technical Document Matrix No: 347 Tesco Stores Ltd. All Rights Reserved. This document is supplied by Tesco for use of the immediate recipient Food Manufacturing Standard TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 1 of 125

2 CONTENTS Introduction to the Tesco Food Manufacturing Standard Site Audit Section 1 HACCP 2 Finished Product Specifications 3 Raw Material and Secondary Site Management 4 Packaging 5 External Areas and Site Security 6 Design and Construction of Premises 7 Design and Construction of Equipment 8 Employee Facilities and Personal Protective Equipment 9 Factory Hygiene 10 Personal Hygiene 11 Process Controls 12 Traceability 13 Allergen Control 14 Foreign Body Controls 15 Foreign Body Detection 16 Product Inspection and Analysis 17 Water and Waste Water Management 18 Product Labelling and Coding 19 Weight, Volume and Count Checks 20 Training Quality Systems Audit 21 Quality Management System 22 Product Development 23 Product Recall/Incident Management 24 Internal Audits 25 Customer Complaints 26 Pest Control 27 Maintenance 28 Calibration 29 Cleaning Programme 30 Transport 31 Medical Screening 32 Employment Agencies 33 Environment 34 Ethical Trading Appendix 1 Raw Material Specifications Appendix 2 Document Review Glossary TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 2 of 125

3 Aim Introduction to the Tesco Food Manufacturing Standard Tesco is committed to ensuring products produced by suppliers are safe, meet legal requirements and are of the agreed quality and that the working conditions of people at Tesco suppliers and ethics applied meet or exceed relevant standards. Objective The Tesco Food Manufacturing Standard (TFMS) sets out the requirements to which suppliers must comply. In some product areas there are additional requirements as detailed in codes of practice. In no circumstances does compliance to the standard replace the need for compliance to relevant legal standards in the country of manufacture or the intended country of sale. Compliance to the standard is in addition to the duty held by the supplier to produce safe and legal food. Scope The TFMS applies to all primary and secondary food suppliers to Tesco. The Standard Structure The Sections and Layout The standard documents Tesco requirements for the Good Manufacturing Practice for food. It is divided into sections by subject, which are then sub divided further to help identify the detailed requirements. Base, Medium, High, Aspiration Each requirement has been allocated a level of Base, Medium, High or Aspiration. These annotations relate to the type of product and or processing which are covered by each requirement. Base These requirements are required in all production facilities irrelevant of the product or process type. Medium These requirements are required in open food handling areas in addition to all of the Base requirements. High TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 3 of 125

4 These requirements are required in all areas that are identified as handling or processing high risk or high care products in addition to all the Base and Medium requirements. Application of Base/Medium/High In a site manufacturing a High Risk product all requirements of the Standard (Base, Medium and High) will apply. i.e. in the high risk area the requirements specified as High apply (in addition to the Base and Medium), in a raw open food area the Medium requirements apply (in addition to Base) and in an area where there is no open product e.g. storage areas, Base requirements apply. Base Medium Base e.g. Raw Material & Packaging Storage Open Food Areas e.g. Preparation Areas High High Risk/ High Care e.g. Despatch Areas Additional Examples Produce Base = Whole produce e.g. whole carrots or swede (including minor trimming) Medium = Prepared produce which is no longer whole e.g. ready to cook carrot batons or vegetable medley High = Prepared ready to eat produce e.g. ready to eat carrot sticks or fruit salad Enclosed Systems Base = Enclosed system areas e.g. pipework Medium = Areas where the product is exposed e.g. tanks where product is accessible. Aspiration Some items have detailed requirements at Base, Medium or High levels but also have some additional elements which Tesco believe will help move standards forward within the food supply base. These are not prescribed requirements but will be viewed favourably by Tesco if implemented. What Good Looks Like In many sections examples are given of how a requirement may be met under the heading of What Good Looks Like. This is intended to provide guidance and clarification of what is required. Due to the variability of the processes and premises compliance to What Good Looks Like does not ensure compliance to a requirement. The supplier must determine the most effective method of complying with Tesco requirements. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 4 of 125

5 PRO To help identify how the requirements should be met each is identified by an x under columns headed PRO. These columns indicate whether the requirement is met through a fully implemented documented procedure, documented records or simple observations. This avoids the need to qualify each requirement with the comment of Documented procedures are required, records must be kept etc. Review The contents of the standard will be regularly reviewed and amended as required. Glossary A glossary has been provided to help with understanding. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 5 of 125

6 Section 1 P R O Section No. Base Medium High Aspiration HACCP Item Detail What Good Looks Like x x 1.1 B HACCP Plan The HACCP Plan must be developed using Codex Alimentarius HACCP principles with reference to relevant legislation, Tesco Codes of Practice and industry guidance. The HACCP Plan must include a detailed scope referencing elements of sections , 1.10, 1.16, x x 1.2 B HACCP Team The HACCP system should be developed by a multi-disciplinary team which must have product specific knowledge and expertise. If expertise is not available, expert advice may be obtained from other sources. The operation of the HACCP system must remain the responsibility of the site. At least one member of the team must have completed a recognised qualification (minimum Intermediate HACCP or equivalent) and the other members must be suitably trained. x x 1.3 B Pre-requisites The basic environmental and operating conditions that are required for the production of safe and legal food must be in place. This covers good manufacturing practices throughout the site. They may include e.g.: Pest control Cleaning procedures Glass/hard plastic control The control measures and monitoring procedures for the pre-requisites are clearly identified and documented. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 6 of 125

7 Waste control x 1.4 B Product A full description of the product must be documented including relevant safety information e.g.: Composition Origin of ingredients Physical or chemical structure (including Aw, ph etc.) Treatment and processing (e.g. heating, freezing, salting) Packaging (e.g. modified atmosphere, vacuum) Storage and distribution conditions (e.g. with specified temperatures) Durability and required shelf-life Instructions for use x 1.5 B Intended Use The intended use of the product must be defined, detailing the end user or consumer and suitability for vulnerable groups must be considered e.g. infants, elderly, and allergy sufferers. x x 1.6 B Flow Diagram A flow diagram covering all steps in the operation including rework and waste must be constructed. This may be generic but it is critical that all process steps are included and identified by product. The diagram must be verified within the production area. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 7 of 125

8 x 1.7 B Hazards All potential hazards that may be reasonably expected to occur for each process step and product must be identified. Hazards identified must be specific to the process step, generic descriptions such as foreign body and micro-organisms are not sufficient. x 1.8 B Hazard Analysis The HACCP team must conduct a hazard analysis to identify hazards which need to be prevented, eliminated or reduced to acceptable levels. The hazard analysis must include: Likely occurrence and severity Survival or multiplication of microorganisms Presence or production of toxins, chemicals or foreign bodies Potential for adulteration/deliberate contamination TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 8 of 125

9 x x 1.9 B Control Measures The team must assess whether an existing prerequisite adequately controls the hazard identified. The team must then consider for the remaining hazards what control measures, if any, exist which can be applied for each hazard which needs to be prevented, eliminated or reduced to acceptable levels. If no control measures can be identified the product/process must be modified so a control measure can be applied. x x A Control Measures The documentation should show links to a specific pre-requisite, rather than generic comment e.g. Pre-requisite. x x 1.10 B Determination of CCPs The Codex decision tree or equivalent must be used to determine if control measures are CCPs (Critical Control Points). A CCP is a step at which control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level. x x 1.11 B Critical Limits Critical limits must be defined and validated to ensure that the product is safe. The process must be capable of operating consistently within the defined limits. For example pest control programme or glass control. Critical limits must be measurable and justification for their use must be documented. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 9 of 125

10 x x 1.12 B Monitoring Monitoring procedures must be established for each CCP to ensure compliance with the critical limits. The monitoring system must be able to demonstrate control and detect loss of control of CCPs. The precision limits and tolerances of the monitoring equipment must be considered when defining limits e.g. tolerance of temperature probes. Monitoring procedures must contain details on how the measurements are taken and the frequency. x x 1.13 B Monitoring Records Monitoring records must be signed by the person doing the monitoring and then verified by an authorised person. x x 1.14 B Corrective Actions The corrective actions to be taken when a CCP deviates from critical limits must be detailed and documented by the HACCP team. The corrective actions must ensure that the CCP has been brought under control and any material that may have been produced whilst the CCP was not in control must be identified, isolated and a full risk assessment completed. Product must be disposed of if the safety of the product is in doubt. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 10 of 125

11 x x 1.15 B Training CCP personnel must have an understanding of HACCP and specific training against the latest version of the relevant monitoring procedure. x x A Training All production personnel should have a basic understanding of HACCP and how it relates to the area they work in. x x 1.16 B Verification The operation of the HACCP plan must be verified to confirm that it is effective. This may include: Internal audits Review of customer complaints Review of hazard measurements e.g. microbiological results. x x 1.17 B Review The HACCP plan must be reviewed at a predetermined frequency (minimum annually) or prior to changes of product/process which may affect product safety. This may include changes in: Process steps Supply or specification of raw materials Ingredients/recipe Packaging, storage or distribution etc. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 11 of 125

12 Section 2 Finished Product Specifications P R O Section No. Base Medium High Aspiration Item Detail What Good Looks Like x 2.1 B Agreed Specifications Agreed Tesco Specifications must be in place for all launched products. Copies of the specifications must be accessible on all production sites. x 2.2 B Review Specifications must be reviewed and re-agreed when changes to product / process are made or to comply with the review date on the specification. x 2.3 B Content Specifications must be fully completed with accurate information that describes the product, packaging and processing details. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 12 of 125

13 Section 3 Raw Material and Secondary Site Management P R O Section No. Base Medium High Aspiration RAW MATERIALS x x 3.1 B Supplier Risk Assessment Item Detail What Good Looks Like All raw material suppliers must be risk-assessed, based on: Inherent risk of the product Volume of product supplied Supplier history Risk assessment must be used to determine: Method of supplier approval Method of supplier monitoring Type and frequency of raw material sampling and testing The raw material supplier risk assessments must be reviewed on an annual basis. x 3.2 B Supplier Approval A supplier approval system must be in place for all raw materials. Approval may include a combination of: Approved site audit report Valid third party certification to a food standard Approved supplier self audit report If the risk assessment indicates that the supplier is low risk (e.g. a low risk commodity such as salt) a supplier self audit may be used. Provided the response to this is satisfactory, an audit may be waived. All raw material suppliers must have a traceability system in place to trace raw materials back to source. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 13 of 125

14 x 3.3 B Third Party Audits If the risk assessment indicates that certification to a third party food standard is sufficient then a valid certificate and audit report must be available on site. x x 3.4 B Audit Requirement If risk assessment indicates that a site audit is required, the site must be audited before supply commences and then, according to an audit schedule. Audits must be completed against a format which encompasses the principles of the Tesco Food Manufacturing Standard. If a critical non-compliance is found at a site that is being audited prior to commencement of supply, then supply must not commence until the corrective action has been completed and verified. If a critical non-compliance is found at a site that is an existing supplier, which could impact on Tesco products in the supply chain, Tesco must be informed immediately. A copy of the audit report must be accessible on site with details of corrective actions. Timescales and corrective actions must be agreed by both parties. The completion of corrective actions must be verified within the agreed timescale. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 14 of 125

15 x 3.5 B Approved Supplier List All suppliers must be approved. Details of suppliers and the raw materials supplied must be kept on an approved supplier list. x x 3.6 B Trained Auditors Supplier audits must be completed by trained auditors with experience in the product area being assessed. x x 3.7 B Agents & Importers Where raw materials are supplied via an Agent/Importer: It is the raw material site and not the Agent/Importer that must be approved The Agent may be assessed by the Tesco supplier as competent to manage approval of the raw material site x x x 3.8 B Raw Material Specifications x 3.9 B Certificates of Analysis/ Conformance The Agent/Importer must be able to demonstrate that they have risk assessed the site against Tesco requirements. All raw materials must have a specification that includes Tesco criteria where relevant See Appendix 1: Raw Material Specifications Raw materials specifications must be agreed by both parties. The supplier risk assessment must define if a Certificate of Analysis or Certificate of Conformance is required. Raw materials may not be used until the details on the certificates have been checked against the raw material specification. Both parties have signed and dated the specification. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 15 of 125

16 x x x 3.10 B Controlled Ingredients Controlled ingredients must be sourced from Valid IT recognised sources as per relevant Codes of Practices where applicable. Code of Practice for Controlled Non GM Ingredients 216 (Tesco UK only) x x 3.11 B Tesco Approved Sources Meat must be sourced from Tesco Welfare Approved Sources unless authorised by the Tesco Technical Manager (Tesco UK only) Code of Practice for Controlled Spice Ingredients 316 (Tesco UK only) Produce must be sourced from Tesco Approved Sources e.g. Natures Choice unless authorised by the Tesco Technical Manager (Tesco UK only). x x 3.12 B Intake Checks All raw materials must be checked by trained staff on receipt according to documented procedures. Intake records must be retained. Checks must include: Hygiene condition of vehicle Packaging integrity Evidence of pest infestation Date/Lot coding Temperature (where required) Product inspection to demonstrate compliance to specification Pallet condition x x 3.13 B Stock Rotation A Stock rotation system must be in place to ensure that raw materials are used within agreed shelf-life. Based on risk assessment checks may also include: Product sampling for retention Product testing (microbiological / chemical / physical / organoleptic) TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 16 of 125

17 x 3.14 B Date Code Controls All materials available for use must have adequate shelf-life remaining for the final use of the material. x x 3.15 B Part-Used Raw Materials x 3.16 B Segregation of Sensitive Materials Opened or part used containers of raw materials must be effectively re-sealed and labelled. Sensitive materials must be suitably segregated to reduce the risk of cross contamination. See sections and x x 3.17 B Non Conforming Materials Non Conforming materials must be rejected at intake. Where this is not possible the Hold and Release procedure must be followed see Section x x 3.18 B Supplier Monitoring Raw material supplier performance must be reviewed minimum annually. This should include results of: Risk assessment Intake inspections Testing Delivery performance SECONDARY SITES AND CONTRACT PACKERS x x 3.19 B Secondary Sites and Contract Packers x x 3.20 B Secondary Sites and Contract Packers The supplier and primary site must be able to demonstrate that they have controls/systems in place to manage product safety, legality and quality when using secondary site and/or contract packers. The supplier and primary site must hold a detailed specification for the product produced/packed by the secondary site and/or contract packer. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 17 of 125

18 x x 3.21 B Secondary Sites and Contract Packer Audits The secondary site and/or contract packer must be approved and have ongoing audits by the supplier and primary site. Audits must be completed against a format which encompasses the principles of the Tesco Food Manufacturing Standard. Suppliers and primary site auditors must be trained against the Tesco Food Manufacturing Standard before auditing secondary sites and/or contract packers. If a critical non-compliance is found at a site that is being audited prior to commencement of supply, then supply must not commence until the corrective action has been completed and verified. If a critical non-compliance is found at a site that is an existing supplier, which could impact on Tesco products in the supply chain, Tesco must be informed immediately. A copy of the audit report must be accessible on site with details of corrective actions. Timescales and corrective actions must be agreed by both parties. The completion of corrective actions must be verified within the agreed timescale. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 18 of 125

19 x x 3.22 B Intake Checks For Products From Secondary Sites and/or Contract Packers All products must be checked by trained staff on receipt according to documented procedures. Intake records must be retained. Checks must include: Hygiene condition of vehicle Packaging integrity Evidence of pest infestation Date/Lot coding Temperature (where required) Product inspection to demonstrate compliance to specification Pallet condition Based on risk assessment checks may also include: Product sampling for retention Product testing (microbiological / chemical / physical / organoleptic) TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 19 of 125

20 Section 4 Packaging P R O Section No. Base Medium High Aspiration x 4.1 B Supplier Risk Assessment Item Detail What Good Looks Like All packaging suppliers must be risk-assessed, based on: Functionality Contact with food Volume of product supplied Supplier history Risk assessment must be used to determine: Method of supplier approval Method of supplier monitoring The packaging supplier risk assessments must be reviewed on an annual basis. x x 4.2 B Supplier Approval A supplier approval system must be in place for all packaging Approval may include a combination of: Approved site audit report Valid 3rd party certificate (BRC-IOP) Approved supplier self audit report If risk assessment indicates that the supplier is low risk, a Supplier Self Audit may be used. Provided the response to this is satisfactory, an audit may be waived. All packaging suppliers must have a traceability system in place to trace packaging. x x A Supplier Approval Food contact packaging suppliers should have BRC IOP certification. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 20 of 125

21 x 4.3 B Third Party Audits If the risk assessment indicates that certification to a third party standard is sufficient then a valid certificate and audit report must be available on site. x x 4.4 B Audit Requirement If risk assessment indicates that a site audit is required, the site must be audited before supply commences, and then according to an audit schedule. Audits must be completed against good manufacturing principles. If a critical non-compliance is found at a site that is being audited prior to commencement of supply, then supply must not commence until the corrective action has been completed and verified. If a critical non-compliance is found at a site that is an existing supplier, which could impact on Tesco products in the supply chain, Tesco must be informed immediately. A copy of the audit report must be accessible on site with details of corrective actions. Timescales and corrective actions must be agreed by both parties. The completion of corrective actions must be verified within the agreed timescale. x 4.5 B Approved Supplier List All suppliers must be approved. Details of suppliers and the packaging supplied must be kept on an approved supplier list. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 21 of 125

22 x x 4.6 B Trained Auditors Supplier audits must be completed by trained auditors with experience in the product area being assessed. x x 4.7 B Agent Approval Where packaging is supplied via an Agent/Importer: It is the manufacturing site and not the Agent/Importer that must be approved The Agent may be assessed by the Tesco supplier as competent to manage approval of the manufacturing site The Agent/Importer must be able to demonstrate that they have assessed the site against Tesco requirements. x x 4.8 B Specifications Packaging specifications must be agreed by both parties. Both parties have signed and dated the specification. Specifications should include the following information where relevant: Material composition Dimensions including thickness and gauge Colour Suitability for use in different storage / handling conditions e.g. temperature / humidity Migration test results x 4.9 B Food Contact Materials All food contact materials (e.g. finished product and work in progress packaging) must comply with "Articles and Materials in Contact with Food" Regulations or equivalent. A written declaration of compliance must be available. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 22 of 125

23 x x 4.10 B Intake Checks All packaging must be checked by trained staff on receipt according to documented procedures. Intake records must be retained. A controlled packaging library is retained. x x 4.11 B Non Conforming Materials Checks must include: Hygiene condition of vehicle Packaging integrity Evidence of pest infestation Date/Lot coding Product inspection to demonstrate compliance to specification Pallet condition Non Conforming materials must be rejected at intake. Where this is not possible the Hold and Release procedure must be followed see section Print text is checked against the packaging library every new print run. The Hold and Release procedure must be used for obsolete packaging materials. x x 4.12 B Supplier Monitoring Packaging supplier performance must be reviewed minimum annually. This should include results of: Risk assessment Intake inspections Delivery performance x x 4.13 B Storage Packaging must be stored in a designated area and be suitable covered to protect from contamination. Similar packaging must be stored separately to prevent incorrect use. x x 4.14 B Part-Used Packaging Part-used packaging which is returned for storage must be suitably covered to protect from contamination. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 23 of 125

24 Section 5 External Areas and Site Security P R O Section No. Base Medium High Aspiration Item Detail What Good Looks Like x x x 5.1 B Site Location The site must comply with local regulations regarding approval or registration of premises and processes. x 5.2 B Site Boundaries Site boundaries must be clearly defined. For example, all UK Food sites must be registered. A site plan must be available on site. x A Site Boundaries Site should be surrounded by secure fencing and monitored by CCTV. x 5.3 B External Maintenance External areas must be kept free from potential pest harbourage. x 5.4 B Grass / Planted Areas When present, vegetation must be kept trimmed and clear from the building (minimum 1 metre clearance). x 5.5 B External Storage Units External units (including silos and tanks) must be locked with restricted access. x x 5.6 B External Storage of Raw Materials, Packaging, Equipment x x x 5.7 B Photographic / Recording Equipment Raw materials, packaging and equipment must not be stored outside. Where unavoidable, items must be protected from deterioration, contamination, pests and must be inspected in detail prior to transfer to the site. The use of photographic/recording equipment must be controlled. Only authorised equipment must be permitted on site. No redundant or stored equipment outside. Visitor / contractor procedures include a declaration of any intended use of photographic/recording equipment. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 24 of 125

25 x x x 5.8 B Control of Visitors, Contractors All visitors and contractors must sign in and when unannounced, prove their identity. All visitors must be accompanied at all times. A system must be in place to manage contractors and a manager must be accountable for their movements. x x x 5.9 B Control of Employees Access to production and storage areas must be restricted to authorised personnel i.e. employees. x x x A Control of Employees A controlled access security system may be in place for all employees e.g. swipe cards, coded access. Security guard is on site. Personnel are encouraged to challenge unknown visitors. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 25 of 125

26 Section 6 P R O Section No. Design and Construction of Premises Base Medium High Aspiration x 6.1 B External Structure and Fabric Item Detail What Good Looks Like The structure and fabric of the building must be suitable for use, weather proof and pest proof. x 6.2 B Internal Structure Walls, floors, ceilings, drains and doors must be designed and maintained to allow effective cleaning. x M Internal Structure Walls, floors, ceilings, drains and doors must be constructed of impervious materials in open food areas. Wall/floor junctions must be coved. Walls must be protected against damage during normal use e.g. crash barriers where appropriate. x H Internal Structure There must be a floor to ceiling physical barrier between low risk and high care / risk. Openings between low risk and high care/risk must be kept to a minimum. Where openings exist they must be risk assessed, managed and verified. x H Internal Structure Where roller lifting doors are in place in high risk / high care areas they must not be in contact with the floor as this may pose a Listeria spp. risk. x A Internal Structure No roller lifting doors are in place in high care / high risk areas. Swing doors with kick plates. Floors are anti-slip TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 26 of 125

27 x 6.3 M Fabrication Joints Fabrication joints must be sealed and free from mould and not pose a foreign body risk. x 6.4 B Floor Gradients Floors must have adequate slope to drainage and not pool water. x 6.5 B Drains Drains must be accessible for cleaning and fitted with screens or traps to prevent pest entry. x M Drains A drain plan must be in place for the entire site. x H Drains Drains must flow from high to low risk areas. A system must be in place to prevent back flow. x A Drains A separate drainage system for high risk/high care from low risk areas. x 6.6 M Walkways Over Lines Walkways and steps over production lines must be fitted with back plates and enclosed sides. x 6.7 B Windows Glass windows and doors in the production and storage areas must be protected from breakage. A risk assessment must be completed on surrounding areas to establish the potential risk of transfer. x B Windows Windows designed to be open, must be suitably proofed to prevent pest entry (including canteens, toilets and locker facilities). x 6.8 B External Doors All external doors must be kept closed when not in use and effectively proofed against pests. Automatic closing doors in place. If strip curtains are fitted, they must be maintained and kept clean. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 27 of 125

28 x M External Doors There must be no external doors in open food handling areas with the exception of identified and controlled fire exits. x H External Doors An interlocked door system must be in place between high risk/high care and low risk for removal of waste or returning of equipment. Fire exits from high risk/high care must be alarmed or tamper evident. x A External Doors Air curtain or automatic closing doors should be fitted to external doors. x 6.9 B Lighting Lighting in all areas must enable safe working and good visibility. Lights must be protected by shatter proof covers and or sleeves. Adequate lighting must be in place above product inspection areas. x A Lighting Lighting designed so that bulbs should be replaced without entering production areas. x 6.10 B Ventilation and Extraction Ventilation and extraction systems must be effective at preventing condensation, excessive dust and pest entry. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 28 of 125

29 x M Ventilation and Extraction x x H Ventilation and Extraction A risk assessment must be conducted to determine the requirement for air filtration. Where air filtration is in place, it must be regularly inspected and replaced. An air filtration system must be in place and be regularly inspected and replaced. x H Ventilation and Extraction Positive air pressure (>5 Pascals) must be in place in high risk areas. The filter sizes used must be risk assessed to ascertain the risk from airborne contamination from the local environment and the likely occurrence of product contamination e.g. time product is exposed. Air socks must be cleaned and maintained at a scheduled frequency air changes per hour depending on number of staff and the size of the room. High care Filtration to a minimum F7 filter size must be in place. High risk Filtration to a minimum F9-H11 filter size must be in place. Air socks must be identified for rotation. x 6.11 B Storage Areas Storage areas must be fit for purpose and maintained in a clean / hygienic condition. x 6.12 B Temperature Controlled Areas Materials must not be stored directly against the walls to allow inspection. Condensate pipes must flow to drain and not drip on product. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 29 of 125

30 x M Temperature Controlled Areas x A Temperature Controlled Areas Condensate pipes must have a trap in the pipe work to prevent a back flow of air from the drains and condensate must be channelled directly out of the area to a drain in fully enclosed pipe work. Doors to temperature controlled areas should be automatic closing or alarmed if not closed. x 6.13 B Production Offices Offices and assessment areas within production / storage areas must be managed so that they do not pose a risk to product. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 30 of 125

31 Section 7 P R O Section No. Design and Construction of Equipment Base Medium High Aspiration x 7.1 B Design and Construction Item Detail What Good Looks Like All equipment must be designed and constructed to enable hygienic cleaning and maintenance. Angles, corners and dead spaces are eliminated. x x 7.2 B Risk Assessment All equipment must be properly specified, commissioned and risk assessed for food safety prior to use. x 7.3 B Construction All surfaces including welds and joints must be smooth and impervious. x 7.4 B Construction Equipment must be constructed from materials that are not susceptible to damage under normal usage and cleaning. x 7.5 B Construction Wearable parts on mechanical equipment e.g. belts, brushes and scrapers that come into contact with food must be of a contrasting colour to the food and be regularly inspected. x 7.6 B Location Equipment must be sited to give access under, inside and around to allow cleaning and servicing. x 7.7 B Mobile Equipment x M Mobile Equipment Mobile equipment e.g. forklift trucks and pallet trucks must be clean, maintained and stored in a suitable area when not in use. Battery charging equipment must not be stored in open food areas. Mobile equipment e.g. forklift trucks and pallet trucks that are used in open food areas must not be used outside. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 31 of 125

32 Section 8 P R O Section No. Employee Facilities and Personal Protective Equipment Base Medium High Aspiration x 8.1 B Employee Facilities x 8.2 B Employee Facilities Item Detail What Good Looks Like Employee facilities (including rest area, toilets, locker areas and changing areas) must be provided and maintained in a clean and hygienic condition. All sites must have a dedicated space to allow employees to leave their own belongings and to change into and out of protective clothing. Separate facilities are provided where appropriate e.g. Abattoir lairage employees separate. x M Employee Facilities x 8.3 B Employee Facilities x 8.4 B Employee Facilities x A Employee Facilities Facilities must be provided for the collection of used/dirty work wear. Changing areas and locker rooms must be sited so employees are not required to go outside after changing into their protective clothing (including footwear). Storage areas for work wear and laundry areas must be clean and protected from contamination. Personal outdoor clothing and shoes must be segregated from work wear and work shoes. Lockers must be kept clean and in good condition. Lockers should have sloping tops and raised off the floor to prevent accumulation of rubbish and to facilitate cleaning. Lockers are clearly partitioned to segregate items. Hooks are provided outside lockers for work wear. Lockers are cleared regularly and not used to store food. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 32 of 125

33 x 8.5 B Employee Facilities x 8.6 B Canteen / Rest Area x x 8.7 B Canteen / Rest Area x 8.8 B Canteen / Rest Area Toilets must be segregated from production and storage areas by a minimum of 2 doors with an intervening ventilated space. The exterior door must be self closing and toilets must be ventilated to the outside. Sites providing food service must complete a documented HACCP for this service. If a contractor is used, their HACCP must be reviewed. Basic hygiene and food safety audits must be completed on a monthly basis by an appropriately trained person. Hygienic storage facilities, including refrigeration must be provided for employees bringing their own food. The temperatures of refrigeration equipment must be monitored. Where preparation equipment (e.g. microwave) is provided it must be inspected. Weekly temperature checks on refrigeration equipment. Consumption and storage of food must only be in designated areas. x 8.9 B Hair Covering Hair covering must be worn by all personnel in production and storage areas. x M Hair Covering Hair and ears must be fully enclosed by the hair covering. Single use hairnets and/or mop caps worn. Beard snoods must be worn to cover beards and moustaches. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 33 of 125

34 x x 8.10 B Protective Clothing Protective clothing must be supplied and worn to minimise the risk of product contamination. Protective clothing must be visually distinctive for staff in specific areas / roles where appropriate i.e. maintenance and cleaning personnel. Different coloured coats/footwear or coloured collars on coats. x M Protective Clothing x H Protective Clothing x 8.11 B Protective Clothing x M Protective Clothing Protective clothing must be maintained in good condition. A procedure must be in place to manage repairs including the control of pins and needles. Protective clothing must be free from external pockets, buttons and not have access to own pockets. Personal clothing above knee height to be fully covered. Exceptions must be agreed by the Tesco Technical Manager. High risk / high care coats must be captive to the area and be protected from contamination until transferred into the area. Protective coats must be visually distinctive and be close fitting at the neck and cuffs. Protective clothing (excluding footwear) must be removed before entering toilets, canteen/rest areas and smoking areas. Protective clothing must be removed in nonproduction areas. A bulk bag containing individual sealed bags from the laundry. Coats incorporating head covering in use. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 34 of 125

35 x A Protective Clothing x x 8.12 B Protective Clothing x x H Protective Clothing All-in-one boiler suits should be phased out. Where protective trousers are required, a knee length coat should be provided. Frequency of changing protective clothing (including re-usable aprons, gloves, high visibility vests and hard hats) and disposable PPE must be defined and verified. Coats must be frequently changed (minimum daily). The frequency of coat laundering and disposable PPE changes must be verified through swabbing. Base visual assessment Medium - frequency is verified through swabbing. x x 8.13 B Laundry Effective laundering of protective clothing must be completed in a hygienic environment and verified. Visual assessment of PPE. Engineering and hygiene work wear must be laundered separately to food production work wear to prevent foreign body contamination. This may be in house or by an external company. In certain circumstances home laundry programmes may be permitted. x x M Laundry Home laundering must not be permitted. Swabbing to verify effectiveness. x H Laundry High risk / high care coats must be laundered separately from coats used in other areas. x 8.14 B Footwear Suitable footwear must be worn. Laundry audits completed including verification of process. No open toes or high heels. Footwear must be kept clean. Temporary shoe coverings may be worn but must TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 35 of 125

36 be of a strong construction and remain intact. x x x M Footwear Footwear must be provided and remain captive to the site. Scheduled footwear cleaning must be in place. Temporary shoe coverings must not be permitted. x x x H Footwear Footwear must remain captive to the area. Insulated Wellington boots Shoes with laces must not be permitted. Scheduled footwear cleaning must be in place (minimum daily). Cleaning effectiveness and frequency must be verified through swabbing and visual assessment. x 8.15 B Hand Washing Sufficient numbers of hand wash or sanitising facilities must be suitably sited at all entrances and throughout production and storage areas where required. Where hand wash facilities are provided, they must have temperature controlled water, effective hand drying facilities and liquid soap. Hand wash sinks in production areas must not be constructed from porous or breakable material. Taps must not be hand operated. Sink waste water must be ducted directly to drain. x M Hand Washing Paper towels or an effective alternative must be used for hand drying. Knee/foot operated or sensors in place. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 36 of 125

37 Paper towel bins must not be hand operated. x H Hand Washing Bactericidal liquid soap and hand sanitiser must be used. Alarm in the production area when reapplication of sanitiser required. x x 8.16 M Changing Procedure x x H Changing Procedure Hand washing facilities and/or hand sanitiser must be located close to employee work stations. Protective clothing must not be worn without hair covering. Personnel must enter high risk / high care via a designated changing area and follow a changing and hand washing procedure. The procedure must follow the order below: Put on a clean hair covering Remove shoes Step over barrier or separation between low and high risk / high care areas. Put on clean high risk footwear Wash and dry hands Put on coat Wash, dry and sanitise hands Enter Production area On exit the procedure must follow the order below: Remove coat Remove footwear Step over barrier or separation between low and high risk / high care areas. Remove hair covering. The procedure may follow the order below: Hair covering Foot covering Wash hands Put on coat Photographs provided to illustrate the changing procedures. Unbreakable reflective surface provided for personnel to confirm that protective clothing is correctly worn. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 37 of 125

38 Section 9 Factory Hygiene P R O Section Base Medium High Aspiration Item Detail What Good Looks Like x 9.1 B General Hygiene Equipment and facilities must be kept in a clean condition. x x 9.2 B General Hygiene There must be a manager accountable for overseeing all cleaning and the standards achieved. x x 9.3 B General Hygiene The site must operate a Clean as You Go Policy with personnel responsible for maintaining a clean and tidy working area. Methods used must not generate aerosols, which could contaminate nearby products or surfaces. x x 9.4 B Cleaning Equipment Personnel must be responsible for keeping their cleaning equipment in a good state of repair and in hygienic condition, replacing when necessary. x 9.5 B Cleaning Equipment Cleaning equipment must be fit for purpose (e.g. heat set bristles in brushes used on food contact surfaces). Cleaning equipment must not be stored in contact with the floor. x M Cleaning Equipment Mops must not be permitted in open food areas. x H Cleaning Equipment High risk / high care cleaning equipment must be stored dry or in disinfectant. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 38 of 125

39 x 9.6 B Cleaning Equipment Separate equipment must be used for food contact and floor cleaning. Cleaning equipment used for toilets must be segregated and visually distinctive. Where in place, colour coding of cleaning equipment must be prominently displayed with equipment. x M Cleaning Equipment Cleaning equipment used in open food areas must not be used outside. x x H Cleaning Equipment A colour coded system must be in place to identify and segregate cleaning equipment between high care / high risk and low risk areas. x 9.7 B Cleaning Equipment Hoses and chemical dosing equipment fitted to water supply must have back flow prevention devices installed. (High pressure lines (>80 psi) do not need backflow protection.) Hoses / cleaning lance ends must not be left on the floor or in tanks when not in use. x H Cleaning Equipment High pressure hoses must not be used. x x 9.8 B Cleaning Chemicals Cleaning chemicals must be kept in a designated store with restricted access. Cleaning chemicals must be suitable for a food environment e.g. no phenolic or scented products (including toilet areas). TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 39 of 125

40 x M Cleaning Chemicals Chemicals storage in production areas must be kept to a minimum. If they are required in production areas they must be secured. x 9.9 B Cleaning Chemicals Cleaning chemicals must be used according to the manufacturers instructions including temperature and dilution. x x x 9.10 B Cleaning Chemicals Chemical dilution checks must be completed at a defined frequency for all dosed equipment (manual/automatic) based on risk assessment. x x 9.11 B Cleaning Chemicals All containers for cleaning chemicals must be correctly labelled and used for their intended purpose only. x 9.12 B Cleaning Areas Designated cleaning areas must be kept in a hygienic condition with obvious flow of equipment from dirty to clean. Chemical drums are secured with a padlock. Areas must have sufficient extraction to minimise condensation build up. x x H Cleaning Areas High risk / high care areas must have their own cleaning facility. Items must not be returned to low risk for cleaning, unless the equipment goes through a heat or disinfection process as it returns to high risk / high care (e.g. cooked back through an oven). x x 9.13 B Production Equipment Equipment must be cleaned off the floor (e.g. on racks or stands). TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 40 of 125

41 x x x 9.14 B Production Equipment Tray washes must be operating at the correct temperature with correct chemical type and dilution. x x 9.15 B Production Equipment Sinks for cleaning production equipment must be clearly identified and must not be used for floor cleaning equipment. Sinks must not be constructed from porous or breakable material and waste water must be ducted directly to drain. x M Production Equipment Tray washes must be monitored and verified. x 9.16 B Production Equipment Clean equipment must be stored in a manner which prevents re-contamination. x x H Production Equipment Stored product contact equipment must be re-disinfected immediately prior to use. x x 9.17 B Waste Waste must be collected in identified containers, correctly disposed of and must not pose an environmental risk. Medium visual inspection and weekly checks. High daily checks and swab verification. Mobile containers such as trays, tote bins are stored in a designated area after cleaning, prior to use. Controlled waste (e.g. unfit meat) must be suitably segregated and managed. x M Waste Waste must be removed from open food areas in such a way that it does not present a cross contamination risk x H Waste Waste must be removed from high risk / high care areas through a one way system. x 9.18 B Waste External waste containers must be covered and segregated. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 41 of 125

42 x x 9.19 B Waste Waste and effluent management must comply with local enforcement requirements. x A Waste Facilities should be in place for segregation and collection of recyclable materials. x x x 9.20 B Waste Any rejected Tesco labelled product must be securely disposed of through a Tesco authorised route or the Tesco packaging must be removed. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 42 of 125

43 Section 10 Personal Hygiene P R O Section Base Medium High Aspiration Item Detail What Good Looks Like x x x 10.1 B Personal Hygiene The site personal hygiene standards must be documented and followed by all personnel, including visitors and contractors. Visitors and contractors must be required to read, understand and accept health, hygiene and safety rules prior to entering the production area. x x x 10.2 B Hand Washing Hand washing or sanitising must be completed e.g. at entry to food handling work areas, after eating, smoking, using the toilet, touching the floor, tying laces or handling unsuitable materials. Hand washing signs must be displayed in toilet areas. x x x H Hand Washing The effectiveness of hygiene procedures with regard to hands must be checked at regular intervals. 1. Wet hands 2. Apply soap 3. Rub palms and back of hands, thumbs, backs of and between fingers repeat each area 5 times. 4. Rinse with water 5. Dry hands 6. Apply and rub in sanitiser. No nail brushes used. Hand swabs and contact plates are taken and assessed following an unannounced but planned programme x x 10.3 B Hygiene Procedure If gloves are worn, hygiene procedures (including frequency of changing) must be in place to ensure that they do not present a risk to product. Personnel must not cough or sneeze over materials or products. Spitting must be prohibited in all areas. TESCO Food Manufacturing Standard Version 2.0 February 2008 Page 43 of 125